U.S. patent number 7,031,628 [Application Number 10/707,578] was granted by the patent office on 2006-04-18 for systems and methods for setting up grid voltages in a tandem pin charging device.
This patent grant is currently assigned to Xerox Corporation. Invention is credited to Song-Feng Mo, John Francis O'Brien, Stephen Ferris Randall, David Sekovski, Jing Qing Song.
United States Patent |
7,031,628 |
Sekovski , et al. |
April 18, 2006 |
Systems and methods for setting up grid voltages in a tandem pin
charging device
Abstract
Systems and methods for setting up grid voltage for a tandem pin
charging device for charging a photoreceptor in a xerographic
printing machine. A charge-generating emitter ratio of a first
charging unit is determined and a first grid voltage is set based
on the charge-generating emitter ratio of the first charging unit.
A charge-generating emitter ratio of a offset voltage is then
determined and a second grid voltage is set, based on the
determined charge-generating emitter ratio of the offset voltage. A
final voltage of a photoreceptor is then compared with a final
target voltage.
Inventors: |
Sekovski; David (Rochester,
NY), Song; Jing Qing (Webster, NY), O'Brien; John
Francis (Fairport, NY), Randall; Stephen Ferris
(Rochester, NY), Mo; Song-Feng (Webster, NY) |
Assignee: |
Xerox Corporation (Stamford,
CT)
|
Family
ID: |
34677049 |
Appl.
No.: |
10/707,578 |
Filed: |
December 22, 2003 |
Prior Publication Data
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Document
Identifier |
Publication Date |
|
US 20050135825 A1 |
Jun 23, 2005 |
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Current U.S.
Class: |
399/50; 399/171;
399/173 |
Current CPC
Class: |
G03G
15/0266 (20130101); G03G 2215/028 (20130101) |
Current International
Class: |
G03G
15/02 (20060101) |
Field of
Search: |
;399/50,168,170,171,173
;250/324,325,326 ;361/225 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Brase; Sandra L.
Claims
What is claimed is:
1. A method for setting the grid voltage of a tandem pin charging
device, the method comprising: determining a charge-generating
emitter ratio of a first charging unit; setting a first grid
voltage based on the charge-generating emitter ratio of the first
charging unit; determining a charge-generating emitter ratio of a
second charging unit; setting a second grid voltage based on the
determined charge-generating emitter ratio of the second charging
unit; and comparing a final voltage of a photoreceptor with a final
target voltage.
2. The method of claim 1, wherein determining the charge-generating
emitter ratio of the first charging unit comprises: determining a
target voltage of a first charging unit grid; determining a target
voltage of a second charging unit grid; measuring at least one
environmental parameter; setting a voltage of the first charging
unit grid to an amount below the target voltage of the first
charging unit grid; setting the second charging unit grid to a
minimum amount; sensing a first photoreceptor voltage; setting the
first charging unit to an amount above the target voltage of the
first charging unit; setting the second charging unit grid to the
minimum amount; and sensing a second photoreceptor voltage.
3. The method of claim 2, further comprising charging the first
charging unit grid and the second charging unit grid by a pin
scorotron device.
4. The method of claim 2, further comprising charging the first
charging unit grid and the second charging unit grid by a pin
corotron device.
5. The method of claim 2, further comprising determining the target
voltage of the first charging to be about five hundred volts.
6. The method of claim 1, wherein determining the charge-generating
emitter ratio of the second charging unit comprises: setting the
first charging unit voltage to a setback target voltage; setting
the second charging unit voltage to a first amount below the final
target voltage; sensing a third photoreceptor voltage; setting the
second charging unit voltage to a second amount below the final
target voltage; sensing a forth photoreceptor voltage.
7. The method of claim 1, further comprising adjusting the second
charging unit voltage to one of a higher voltage and a lower
voltage when the final voltage of the photoreceptor is not within a
predetermined range of the target voltage.
8. The method of claim 7, further comprising counting a number of
voltage adjustments with a loop counter and indicating a fault when
the number of voltage adjustments reaches a predetermined
amount.
9. The method of claim 8, further comprising indicating a fault
when the loop counter counts ten voltage adjustments.
10. The method of claim 7, further comprising making no adjustment
to the second charging unit voltage when the final voltage is
within the predetermined range of the target voltage.
11. The method of claim 7, further comprising adjusting the offset
voltage in increments of about five volts.
12. The method of claim 7, further comprising determining that the
predetermined range is one of about ten volts above the target
voltage and about ten volts below the target voltage.
13. The method of claim 1, further comprising determining the final
target voltage to be about six hundred and fifty volts.
14. The method of claim 1, further comprising measuring the final
voltage of the photoreceptor with an electrostatic volt meter.
15. A charging system control system that controls the grid voltage
setup process of a tandem pin charging device, comprising: a first
charging unit target voltage determining circuit, routine or
application that determines the target voltage for a first charging
unit; a second charging unit target voltage determining circuit,
routine or application that determines the target voltage of a
second charging unit; a charge-generating emitter ratio determining
circuit, routine or application that determines the
charge-generating emitter ratio of at least one of the first
charging unit and the second charging unit; and a final voltage
comparing circuit, routine or application that compares a final
voltage applied to a photoreceptor with a final target voltage.
16. The charging system control system of claim 15, further
comprising an input/output interface for inputting data from at
least one of an electronic volt meter and an environmental data
source to at least one of a memory, a first charging unit target
voltage determining circuit, routine or application, a second
charging unit target voltage determining circuit, routine or
application, a charge generating emitter determining circuit,
routine or application and a final voltage comparing circuit
routine or application.
17. The charging system control system of claim 15, further
comprising a controller for controlling at least one of the first
charging unit voltage setting device and the second charging unit
voltage setting device.
18. The charging system control system of claim 17, wherein the
input/output interface outputs commands from the controller to at
least one of a first charging unit voltage setting device and a
second charging unit voltage setting device.
19. The charging system control system of claim 15, further
comprising a memory for storing data from at least one of the
electronic volt meter and the environmental data source.
20. The charging system control system of claim 19, wherein the
memory is a nonvolatile memory.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to systems and methods for controlling
process parameters for a xerographic printing machine.
2. Description of Related Art
The use of charging devices for photoreceptors in xerographic
printing is well known in the art. Typically, such charging devices
may be one or more of a corotron, a dicorotron, a pin corotron, a
scorotron, a discorotron, and/or a pin scorotron. Such charging
devices may include a chamber arranged with one or more
charge-generating emitters such as, for example, a wire, a
dielectric wire, or a pin array. Some charging devices may also
include a control grid to regulate and control the charge provided
to the photosensitive member. In this way, the photosensitive
member may receive a uniform charge at a desired potential.
As known in the art, a key characteristic of a charging device is
the di/dV ratio or charge generating emitter ratio of the
charge-generating emitter of the charging device. The di/dV ratio
is also known as the "slope" of the emitter, and is generally
expressed in units of Amperes per volt-meter. Typically, charging
devices having a high slope have high overshoot output voltage,
i.e., generate a voltage on the photoreceptor that is above the
grid voltage, and have poor charging uniformity. In a pin
scorotron, the ions generated from the coronode are accelerated by
the field force past the screen or grid to reach the photoreceptor
surface, thus increasing the surface potential beyond the grid
voltage.
When the surface potential reaches the same voltage as the voltage
on the screen or grid, there is no electrostatic field between the
screen and the photoreceptor. However, since the ions have high
residual momentum as the ions approach the grid from the coronode
side, the ions will continue to penetrate the grid and build up a
space charge. This extra space charge drives some ions to the
photoreceptor surface, increasing the surface potential further,
until the repulsion field force is large enough to prevent further
ion transport. The overshoot voltage may be defined as the extra
difference in voltage, above the grid voltage, that the
photoreceptor potential needs to reach to prevent further ion
transport.
As the current flowing from each pin differs from pin to pin, the
time to reach the final overshoot voltage also varies from pin to
pin. The time required for charging a surface under the charging
device is determined by the width of the charging device and the
process speed of the photoreceptor surface being charged past the
charging device. This time may be limited by practical
considerations, and not all pins may reach the ultimate overshoot
voltage. All of this tends to limit the voltage uniformity of
practical pin devices.
However, uniform photoreceptor charging is required to achieve
high-quality xerographic results. As such, various ways to achieve
desired levels of uniform charging are known. For example, U.S.
Pat. No. 6,459,873 to Song et al. discloses a DC pin scorotron
charging apparatus for charging a photoreceptor to a desired
voltage. In this charging device, a first DC pin scorotron charging
device initially charges the photoreceptor to an intermediate
overshoot voltage. A second DC pin scorotron charging device
thereafter uniformly charges the photoreceptor to the final
voltage. The first charging device provides a generally high
percent open control grid area, a generally high emitter slope, and
a generally high emitter pin current. The second charging device
provides a generally low percent open control grid area, a
generally low emitter slope, and a generally low emitter pin
current.
The goal of the first charging device is to provide the majority of
the charging ions to the photoreceptor. The first charging device
is designed as a high slope device with high screen open area, high
coronode voltage (current) and close pin-to-screen spacing. This
design tends to result in high overshoot voltage. Therefore, the
screen voltage is purposely set lower than the required charging
voltage. An offset voltage is defined as the grid voltage
difference between the first charging device and the second
charging device. The offset voltage is important and should be
greater than the overshoot voltage of the first charging
device.
The second charging device provides "uniform" charge leveling with
little charge-up needed to bring the entire voltage of the surface
being charged to the desired photoreceptor potential as uniformly
as possible. Because the first charging device has provided most of
the charging ions to the photoreceptor, the first charging device
significantly reduces the required charging capability of the
second charging device. Thus, the second charging device may be a
low slope, low overshoot device. This may be accomplished by
decreasing the screen open area, for example, to less than 50 60
percent, lowering the coronode voltage (current) and/or increasing
the pin-grid spacing in the second charging device relative to the
first charging device. Because each of these changes may improve
the charging uniformity of the second charging device relative to
the first charging device, the final photoreceptor potential should
be close to the applied screen voltage on the second charging
device with little overshoot.
SUMMARY OF THE INVENTION
In an image forming device that uses multiple charging devices to
charge the photoreceptor to a final voltage, it is desirable that
the offset voltage, that is, the voltage difference between the
grid voltages of the different charging devices, be set
appropriately. If the offset voltage is too small, the overshoot
voltage of the first device results in the photoreceptor charging
potential being higher than the grid voltage of the second device.
In this case, the second device is effectively shut off.
Consequently, the charging uniformity on the photoreceptor will be
poor, because the system fails to benefit from the charge
uniformity the second charging device is able to create. If the
offset voltage is too large, a high charge-up requirement is
imposed on the second device. Because the second charging device is
a lower slope device, it may be not be capable of achieving the
ultimate desired charge potential on the photoreceptor from all of
the pin emitters, thus reducing the charging uniformity of the
charge on the photoreceptor.
Static set points generally cannot be used to set the grid voltage
of the first and second charging devices because such static set
points cannot meet the performance requirements for charging
photoreceptors. Variations in charging performance may occur, for
example, because of deviations in mechanical tolerances, variations
in environmental conditions, such as, for example, temperature,
pressure, and/or humidity, and the like. In addition, mechanical
tolerance deviations, as well as environmental variations, vary
over time. Thus, ultimate copy quality is affected over time, as a
result of mechanical and environmental variations. This results in
increased service calls related to copy quality problems. As such,
there is a need for a low cost solution for controlling the offset
voltage.
This invention provides systems and methods for automatically
setting up the grid voltages for a dual charger charging
system.
This invention separately provides methods that automatically
compensate for mechanical and environmental effects to ensure the
appropriate set points for a dual-charger charging system.
This invention separately provides systems and methods for
substantially improving charging uniformity by exploiting the
maximum benefits of the second charging unit of a dual-charger
charging system.
This invention separately provides systems and methods for enabling
the use of low cost devices such as pin scorotrons to replace
higher cost devices to enhance copy quality and reduce service
calls related to copy quality problems.
In various exemplary embodiments according to this invention, the
final ideal photoreceptor potential and the preferred grid voltage
of the second unit are set to the same voltage. The interim ideal
photoreceptor potential after passing the first charging device,
may be, for example, 50 70 volts lower than the final ideal
photoreceptor voltage. Due to the high overshoot capability of the
first charging unit, the grid voltage of the first charging unit
should be set even lower.
In various exemplary embodiments, systems and methods according to
this invention may be used to compensate for variations in charging
conditions due to mechanical tolerances and/or environmental
conditions. For example, during machine warm-up, the first charging
unit of the dual pin scorotron system is enabled, while the second
charging unit is disabled. Then, the grid voltage of the first
charging unit is started at a low setting and is increased in
desired increments. An electrostatic voltage meter (ESV) may be
used to measure the interim photoreceptor potential after the
photoreceptor is charged by the first charging device. The measured
interim photoreceptor potential from the ESV is used in a
closed-loop feed-back system to adjust the first voltage of the
first charging unit. In various exemplary embodiments, these closed
loop feed-back adjustment systems and methods enable the interim
photoreceptor potential, after passing the first charging device,
to be about 40 volts less than the second grid voltage and final
photoreceptor potential. Thus, the interim photoreceptor potential,
after passing the first charging device, is at a desirable point
for the second charging device to add additional charge to the
photoreceptor and to reduce voltage nonuniformity.
These and other features and advantages of this invention are
described in, or are apparent from, the following detailed
description of various exemplary embodiments of the systems and
methods according to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Various exemplary embodiments of the invention will be described
with reference to the accompanying drawings, in which like elements
are labeled with like numbers, and in which:
FIG. 1 shows one exemplary embodiment of a dual pin scorotron
system usable with this invention and a corresponding graph
illustrating the resulting photoreceptor potential;
FIG. 2 is a flowchart outlining one exemplary embodiment of a
method for automatically setting up the grid voltages of a
dual-charger charging system;
FIG. 3 is a flowchart outlining in greater detail one exemplary
embodiment of the method for determining the slope of the first
grid of FIG. 2;
FIG. 4 is a flowchart outlining in greater detail one exemplary
embodiment of the method for determining the offset voltage slope
of FIG. 2;
FIG. 5 is a flowchart outlining in greater detail one exemplary
embodiment of the method for setting up the voltages on the grids
of the dual-charger charging system of FIG. 2; and
FIG. 6 is a block diagram outlining one exemplary embodiment of a
charging system control system usable to determine charging grid
voltages for a multiple charging device charging system.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 illustrates one exemplary embodiment of a dual pin scorotron
system 100 and a graph 150 that illustrates the measured voltage on
a photoreceptor 130 as the photoreceptor 130 passes a first
charging unit 110 and a second charging unit 120 of the dual pin
scorotron system 100. In a typical dual pin scorotron system 100,
ions 116 generated from a pin scorotron 112 of the first charging
unit 110 are accelerated by a field force past a first grid 114 to
reach the photoreceptor 130, thus increasing the surface potential
of the photoreceptor 130. When the surface potential V.sub.1C of
the photoreceptor 130 reaches the same voltage V.sub.grid1 as the
voltage on the first grid 114, there is no electrostatic field
between the first grid 114 and the photoreceptor 130. However,
since the ions 116 have high residual momentum as they approach the
first grid 114 from the first charging unit 110, the ions 116 will
continue to penetrate the first grid 114 and build up a space
charge. This extra space charge drives some ions 116 to the surface
of the photoreceptor 130. This further increases the surface
potential V.sub.1C of the photoreceptor 130 until the repulsion
field force is large enough to prevent further transport of the
ions 116 through the first grid 114. As stated earlier, the
overshoot voltage V.sub.1O is defined as the extra difference in
voltage that the surface potential V.sub.1C of the photoreceptor
130 can reach above the voltage V.sub.grid1 of the first grid
114.
The first charging unit 110 provides a majority of ions 116 to the
photoreceptor 130 and is typically a high slope device with a high
screen open area, higher voltage and close pin-to-grid spacing. As
such, the first charging unit 110 tends to cause high overshoot
voltage. Thus, the grid voltage V.sub.grid1 of the first grid 114
is purposely set lower than the required charging voltage V.sub.1t
for the first charging unit 110. As stated earlier, the offset
voltage V.sub.O is defined as the difference in grid voltage
between the first charging unit 110 and the second charging unit
120.
A curve 158 of the graph 150 illustrates the change in voltage as
the photoreceptor 130 passes both the first charging unit 110 and
the second charging unit 120. A graph line 156 represents the
target voltage of the photoreceptor 130 before passing either of
the first charging unit 110 and the second charging unit 120. As
illustrated, a graph line 152 represents the target surface
potential V.sub.1t of the photoreceptor 130 after passing the first
charging unit 110. This first or interim target surface potential
V.sub.1t is, for example, 500 volts. As illustrated by the curve
158, the voltage V.sub.C of the photoreceptor 130 is not uniform,
and is, in fact highly varied, after passing the first charging
unit 110. However, the voltage V.sub.C becomes quite uniform after
the photoreceptor 130 passes the second charging unit 120. A graph
line 154 represents the final target voltage V.sub.Ft after the
photoreceptor 130 passes the second charging unit 120. This final
target voltage V.sub.Ft is, for example, 650 volts.
The second charging unit 120 may be a low slope, low overshoot
device having a decreased screen open area with lowered voltage and
increased pin grid spacing relative to the first charging unit 110.
Thus, the second charging device 120 has an improved charging
uniformity relative to the first charging unit 110. In this
embodiment, the final photoreceptor potential V.sub.2C may be close
to the applied voltage V.sub.grid2 on a second grid 124 of the
second charge device with very little overshoot. Ions 126 may be
generated from a pin scorotron 122.
In one exemplary embodiment, the first charging unit 110 may have a
large grid open area (70 percent) and a high pin current (9.9
uA/pin). The first charging unit 110 may have a slope of 1.8
uA/(m-V) or more. The overshoot voltage for such a first charging
unit 110 may be typically about 100 to 170 volts. The second
charging unit 120 may have a small grid open area (50 percent) with
a low pin current (7.5 uA/pin). The final target charging potential
V.sub.Ft of the photoreceptor may be, for example, 650 volts.
Because the overshoot V.sub.1O of the first charging unit 110 may
be about 100 to 120 volts, the voltage V.sub.grid1 of the first
grid 114 may be set at about 500 volts. Thus, the photoreceptor
potential after passing the first charging unit 110, i.e. the
voltage V.sub.1C on the photoreceptor, may be about 600 to 620
volts.
As stated previously, various factors, such as coronode surface
conditions and differences in photoreceptor initial voltage across
the surface at the entrance to the device, may affect performance
and cause poor charging uniformity after passing the first charging
unit 110. Because the first charging unit 110 delivers the majority
of charging current and brings the potential close to the desired
voltage V.sub.Ft (650 volts), the required charging range for the
second device need only be, for example, about 100 volts to 30
volts. Thus, the second charging unit 120 may be a low slope and
low overshoot device. With low overshoot, the photoreceptor
potential V.sub.2C may stay close to the final target voltage
V.sub.Ft of 650 volts. The actual final potential V.sub.2C depends
on the voltage V.sub.grid2 of the second grid 124 and the
photoreceptor potential V.sub.1C after passing the first charging
unit 110 and may be insensitive to other factors. The required
minimum current per pin scorotron 122 for the second charging unit
120 will depend on the process speed of the photoreceptor 130.
With the dual pin scorotron system 100 of this embodiment,
traditional low-cost pin scorotrons may be used as the first and
second charging devices 110 and 120. As a result, the dual pin
scorotron system 100 may be used to achieve a much higher charging
uniformity than a traditional single charging unit device. As such,
when using a dual-charger charging system according to this
invention, the difference between the photoreceptor initial voltage
and the intercept voltage of the second charging unit is small.
Thus, excellent uniformity can be achieved even though the slope of
the second charging unit 120 is relatively low.
FIG. 2 illustrates an exemplary embodiment of a method for
automatically setting up the grid voltages V.sub.grid1 and
V.sub.grid2 of a dual pin scorotron system according to this
invention. As shown in FIG. 2, operation of the method begins in
step S100, and proceeds to step S200, where the slope of
V.sub.grid1 to the obtained charge V.sub.1C on the charge retentive
surface due to the first grid charging device is determined. Then,
in step S400, the desired target offset voltage .DELTA.V.sub.grid
between the target voltage V.sub.1t on the grid of the first
charging unit and the combined target voltage V.sub.Ft of the
charge retentive surface is determined based on the slope of
V.sub.grid2 to the charge obtained on the charge retentive surface
due to the second charging device. Next, in step S600, the final
voltage V.sub.2C (or V.sub.F) is adjusted, if necessary to come
within the desired tolerance of the target voltage V.sub.Ft.
However, it should be appreciate that it may not be necessary to
set or adjust the final voltage V.sub.2C in the event that the
final voltage V.sub.2C is already within a desired tolerance of the
target voltage V.sub.Ft. Operation then continues to step S800
where operation of the method ends.
FIG. 3 is a flowchart outlining in greater detail one exemplary
embodiment of the method for determining the slope of V.sub.grid1
to V.sub.1C for the first charging grid of step S200 according to
this invention. As shown in FIG. 3, operation begins in step S200,
and proceeds to step S210, where the target voltage V.sub.1t to be
imparted on the charge retentive surface by the first grid is
determined, selected or input. Then, in step S220, the combined
target voltage V.sub.Ft to be imparted to the charge retentive
surface by the first charging device and second charging device
together is determined. In various exemplary embodiments, the
target voltage V.sub.1t on the charge retentive surface may be 500
volts, while the target voltage V.sub.2t on the charge retentive
surface may be 650 volts, i.e. that the first and second charginge
devices together impart a total charge V.sub.2C of 650 volts, on
the charge retentive surface. Operation then continues to step
S230.
In step S230, environmental sensor data is input or read. In
various exemplary embodiments, the input or read environmental data
is stored in memory. In various exemplary embodiments, memory
comprises a non-volatile memory. However, it should be appreciated
that data may be stored in any type of known or later-developed
memory device. This environmental data may include such information
such as, for example, temperature and/or humidity. Next, in step
S240, the first grid is set to a first test voltage V.sub.grid1a.
In various exemplary embodiments, this first test voltage level is
100 volts below the target voltage V.sub.1t of the first grid.
Then, in step S250, the second grid voltage is set to a minimum
value such as 0 volts. Operation then continues to step S260.
In step S260, the selected first test voltage V.sub.grid1a is
applied to first grid as charges are applied to the charge
retentive surface by the first charging device. Then, in step S270,
the charge imparted to the charge retentive surface V.sub.1Ca with
the first grid voltage set to the first test voltage V.sub.grid1a
is read and stored in memory. In various exemplary embodiments, the
charge is read using an electronic voltage meter or electrostatic
voltage meter (ESV). Next, in step S280, the first grid voltage is
set to a second test voltage V.sub.grid1b. In various exemplary
embodiments, this second test voltage V.sub.grid1b is 100 volts
above the target voltage V.sub.1t of the first grid. Operation then
continues to step S290.
In step S290, the grid voltage V.sub.grid2 of the second charging
unit is again set to a minimum value, such as 0 volts. Next, in
step S300, the selected second test grid voltage V.sub.grid1b is
applied to the first grid as the grid charges are applied to the
charge retentive surface by the first charging device. Then, in
step S310, the charge imparted to the charge retentive surface
V.sub.1Cb, with the voltage on the first grid set to the second
test voltage V.sub.grid1b is read and stored in memory. Operation
then continues to step S320.
In step S320, the slope of V.sub.grid1 to V.sub.1C is determined
using the stored charge values V.sub.1Ca and V.sub.1Cb obtained by
applying the first and second test voltages V.sub.grid1a and
V.sub.grid1b to the first grid. As described earlier, the slope of
V.sub.grid1 to V.sub.1C is expressed in units of Amperes per
volt-meter (A/vm). Based on the response curve for the first
charging grid, the voltage level V.sub.grid1 on the control grid of
the first charging unit that will charge the charge retentive
surface to the desired target potential voltage V.sub.1t can be
determined. Operation then continues to step S330, where operation
of the method ends.
FIG. 4 is a flowchart outlining in greater detail one exemplary
embodiment of the method for determining the response curve of the
second charging grid according to this invention. As shown in FIG.
4, operation of the method begins in step S400 and proceeds to step
S410, where, based on the slope of V.sub.grid1 to V.sub.1C, the
grid voltage on the control grid of the first charging unit is set
to a voltage level that will achieve a charge of V.sub.1t on the
charge retentive surface. Then, in step S420, the offset voltage
.DELTA.V.sub.grid is set to a first test voltage
.DELTA.V.sub.grida. In various exemplary embodiments, the first
offset test voltage .DELTA.V.sub.grida is 100 volts "more" than the
intermediate target voltage V.sub.1t. Typically, the charge
retentive surface is regularly charged. In this case
.DELTA.V.sub.grida is -100V (i.e., 100 volts below V.sub.grid1).
Next, in step S430, the charge retentive surface is charged with
the .DELTA.V.sub.grida. Then, in step S440, the charge level
imparted to the charge retentive surface V.sub.2Ca is sensed and
stored in memory. Operation then continues to step S450.
In step S450, the offset voltage .DELTA.V.sub.grid is set to a
second test voltage .DELTA.V.sub.gridb. In various exemplary
embodiments, the second test voltage .DELTA.V.sub.gridb is 200
volts "more" than the intermediate target voltage V.sub.1t. Thus,
when the charge retentive surface is negatively charged,
.DELTA.Vgridb is -200V. Then, in step S460, the charge retentive
surface is charged with the first charging grid set to achieve the
intermediate target voltage of V.sub.1t and the second charging
grid is set to achieve an offset voltage .DELTA.V.sub.grid of
.DELTA.V.sub.gridb. Next, in step S470, the charge imparted to the
charge retentive surface V.sub.2Cb is sensed and stored in memory.
Operation then proceeds to step S480.
In step S480, based on the stored charge levels V.sub.2Ca and
V.sub.2Cb corresponding to .DELTA.V.sub.grida and
.DELTA.V.sub.gridb, the slope of the offset voltage
.DELTA.V.sub.grid to V.sub.2C is determined. Operation then
continues to step S490, where operation of the method returns to
step S600.
FIG. 5 is a flowchart outlining in greater detail one exemplary
embodiment of the method for determining whether the final
photoreceptor voltage V.sub.2C is within an acceptable range or
tolerance of the target final voltage V.sub.Ft of FIG. 2 according
to this invention. Operation of the method begins in step S600, and
proceeds to step S610, where the voltages V.sub.grid1 and
V.sub.grid2 on the control grid of the first and second charging
devices are set based on the determined slopes for V.sub.grid1 and
.DELTA.V.sub.grid, to the achieve the target voltage V.sub.Ft.
Then, in step S620, the charge retentive surface is charged using
the first and second charging devices having the control grids set
based on V.sub.grid1 and .DELTA.V.sub.grid. Next, in step S630, the
actual final voltage V.sub.Fa on the charge retentive surface,
caused by first and second control grids being set as described is
read and stored. Operation then continues to step S640.
In step S640, a determination is made whether the actual final
voltage V.sub.Fa is within a predetermined tolerance of the target
voltage V.sub.Ft. In various exemplary embodiments, the tolerance
for the actual final voltage V.sub.Fa can be .+-.10 volts of the
target voltage V.sub.Ft. If, in step S640, a determination is made
that the final actual voltage V.sub.Fa is within an acceptable
tolerance of the target voltage V.sub.Ft, operation jumps to step
S710. Otherwise, processing proceeds to step S650.
In step S650, the offset voltage .DELTA.V.sub.grid is adjusted by
altering the offset voltage .DELTA.V.sub.grid by a determined
increment. For example, if the actual voltage V.sub.Fa is too high,
the offset voltage .DELTA.V.sub.grid is adjusted up by the
determined increment. If the actual voltage V.sub.Fa is too low,
the offset voltage .DELTA.V.sub.grid is adjusted down by the
determined increment. It should be appreciated that the determined
increment can be predetermined or can be dynamically determined or
determined on the fly. For example, the determined increment can be
determined based on the difference between the actual and target
final voltages V.sub.Fa and V.sub.Ft. In various exemplary
embodiments, a reasonable predetermined increment is 5 volts. Next
in step S660, the charge retentive surface is charged using the
first and second charging devices having the control grids set
based on V.sub.grid1 and .DELTA.V.sub.grid. Operation then
continues to step S670.
In step S670, the voltage value V.sub.Fa imparted to the charge
retentive surface based on the new value for .DELTA.V.sub.grid is
again sensed and stored. Then, in step S680 a loop counter,
representing the number of adjustments that have been made to the
offset voltage .DELTA.V.sub.grid is incremented. Then, in step
S690, a determination is made whether the value of the loop counter
is equal to the maximum allowable number of iterations. If the
maximum allowable number adjustments has been made, operation
proceeds to step S700. Otherwise, operation returns to step S640.
In step S700, a fault indication is output. Operation then
continues to step S710, where operation of the method returns to
step S800. Thus, once either a fault indication has been output or
the measured voltage on the charge retentive surface V.sub.Fa is
determined to be within the acceptable tolerance of the target
voltage V.sub.Ft, operation of the method returns to step S800.
FIG. 6 is a block diagram outlining one exemplary embodiment of a
charging system control system 200 according to this invention. As
shown in FIG. 6, the charging system control system 200 has an
input/output interface 210 that is linked to an electronic volt
meter 300 (or any other appropriate charging sensing device) by a
link 310. The input/output interface 210 is also linked to an
environmental data source 400 by a link 410, a first charging unit
voltage setting device 500 by a link 510, and a second charging
unit setting device 600 by a link 610. The charging system control
system 200 also includes a controller 220, a memory 230, a first
charging unit target voltage determining circuit, routine or
application 240, a second charging unit target voltage determining
circuit, routine or application 260, a slope determining circuit,
routine or application 250, and a final voltage comparing circuit,
routine or application 270.
Each of the links 310 610 can be any known or later developed
connection system or structure usable to connect the respected
devices to the charging system control system 200. It should also
be understood that the links 310 610 do not need to be of the same
type.
The memory 230 can be implemented using any appropriate combination
of alterable volatile or non-volatile memory, or non-alterable or
fixed memory. The alterable memory whether volatile or non-volatile
can be implemented using any one or more of static or dynamic RAM,
a floppy disk and disk drive, a writable or rewritable optical disk
and disk drive, a hard drive, flash memory or the like. Similarly,
the non-alterable or fixed memory can be implemented using any one
or more of ROM, PROM, EPROM, EEPROM, and gaps in an optical ROM
disk, such as a CD ROM or DVD ROM disk and disk drive, or the
like.
In one exemplary embodiment of the operation of the charging system
control system 200 according to this invention, environmental data
is read by the environmental data source 400. The read
environmental data is forwarded from the environmental data source
400 over the link 410 to the charging system control system 200.
The received environmental data is output through the input/output
interface 210 and stored into the memory 230. A first charging unit
target voltage is determined by the first charging unit target
voltage determining circuit, routine or application 240. Next, the
second charging unit target voltage is determined by the second
charging unit target voltage determining circuit, routine or
application 260. The first charging unit voltage setting device
500, based on control signals from the controller 220, sets the
control grid voltage for the first charging device to a first value
below the determined first charging unit target voltage.
The first charging device is then used to charge a photoreceptor or
other charge-retentive surface. The charge applied to the
charge-retentive surface by the first charging device is then read
by the electrostatic volt meter 300. The read charge is input by
the electronic volt meter 300 over the link 310 to the charging
system control system 200. The received data is input through the
input/output interface 210 and stored in the memory 230.
The first charging unit voltage setting device 500, based on
control signals from the controller 220, sets the control grid
voltage for the first charging device to a second value above the
determined first charging unit target voltage. The first charging
device is then again used to charge a photoreceptor or other
charge-retentive surface. The charge applied to the
charge-retentive surface by the first charging device is then again
read by the electronic volt meter 300. The read charge is input by
the electronic volt meter 300 over the link 310 to the charging
system control system 200. The received data is input through the
input/output interface 210 and stored in the memory 230. The
charge-generating emitter ratio (slope) of the first charging unit
is then determined by the charge-generating emitter ratio
determining circuit, routine or application based on the first and
second voltages the control grid of the first charging device was
set to and the high and low voltages read by the volt meter 300 and
stored in memory 230.
Based on the charge-generating emitter ratio of the first grid as
determined by the charge-generating emitter ratio determining
circuit, routine or application 250, the first charging unit target
voltage determining circuit, routine or application 240 determines
a setback target voltage and stores this data in the memory 230.
The first grid voltage is then set to the setback target voltage by
the first charging unit voltage setting device 500 based on control
signals from the controller 220. The second charging unit voltage
setting device 600 then, based on control signals from the
controller 220, sets the control grid of the second charging device
to 100 volts below the final target voltage. The first and second
charging devices are then used to charge the charge retentive
surface. The electronic volt meter 300 then reads the voltage on
the charge retentive surface and stores the voltage in the memory
230. The second charging unit voltage setting device 600 then sets,
based on control signals from the controller 220, the control grid
of the second charging device to 100 volts above the final target
voltage. The first and second charging devices are then used to
charge the charge retentive surface. The electrostatic volt meter
300 then reads the voltage on the charge retentive surface and
stores the voltage in the memory 230. The charge-generating emitter
ratio determining circuit, routine or application 250 then
determines the slope of the second charging unit based on the high
and low voltages read by the volt meter 300 and stored in the
memory 230. The second charging unit target voltage determining
circuit, routine or application 260 determines the second target
voltage of the second charging unit.
The final voltage comparing circuit, routine or application 270
determines whether the final actual photoreceptive voltage on the
charge retentive surface is within an acceptable range of the
target final voltage, and thus whether the setup process is
complete. The grid voltage of the second charging device is set to
the determined second target voltage by the second charging unit
voltage setting device 600. The first and second charging devices
are then used to charge the charge retentive surface. The voltage
on the charge retentive surface is then read by the electrostatic
volt meter 300 and stored in the memory 230. The final voltage
comparing circuit, routine or application 270 then determines
whether the actual final voltage is within a determined tolerance
of the target final voltage. If the actual final voltage is within
the determined tolerance of the final target voltage, the setup
process is complete. If the actual final voltage is not within a
determined tolerance of the final target voltage, the second
charging unit target voltage setting device 260 adjusts the second
target voltage in determined increments and this process is
repeated until the actual final voltage is within the determined
tolerance of the target final voltage, or after some predetermined
number of increments have been performed. In that case, a fault
indication is output by the final voltage comparing circuit,
routine or application 270.
It should also be understood that each of the circuits, routines
and/or applications shown in FIG. 6 can be implemented as portions
of a suitably programmed general purpose computer. Alternatively,
each of the circuits, routines and/or applications shown in FIG. 6
can be implemented as physically distinct hardware circuits using a
digital signal processor or using discrete logic elements or
discrete circuit elements. The particular form each of the
circuits, routines and/or applications in FIG. 6 will take is a
design choice and will be obvious and predictable to those skilled
in the art. It should also be appreciated that the circuits,
routines and/or applications shown in FIG. 6 do not need to be of
the same design.
While this invention has been described in conjunction with the
specific embodiments outlined above, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, the preferred embodiments of
the invention, as set forth above, are intended to be illustrative,
not limiting. Various changes may be made without departing from
the spirit and scope of the invention.
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